Rockwell Automation CompactLogix 5380/5480 Complete Guide

Fault 2: The SD card write protection switch is locked.

Solution: Turn the mechanical switch on the side of the SD card to the unlock position. Note that 9509-CMSDCD4 does not have a write protection switch.

Important: It is strongly recommended to only use SD cards provided by Rockwell Automation, as third-party cards may have compatibility issues such as inability to recognize or data corruption.

Mandatory installation of end caps

The rightmost module of each CompactLogix 5380/5480 system must be equipped with an end cap 5069-ECR. The end cap is provided with the controller. If powered on without installing the end cap, it may pose a risk of electric shock and equipment damage, as the end cap covers the exposed internal interconnect pins on the last module.

Common errors on site: Engineers forget to move the end cap to the new rightmost position after expanding I/O, resulting in random faults or short circuits during system operation. Solution: After adding or removing modules, be sure to check if the end cap is located on the far right.

Key points for wiring of Removable Terminal Block (RTB)

The CompactLogix 5380 and GuardLogix 5380 controllers require two types of RTBs:

MOD power supply: 4-point RTB, providing 24V DC to the controller logic.

SA power supply: 6-point RTB, used to transmit on-site power (SA Power) to the I/O module.

There are two types of RTB kits:

5069-RTB64-SCREW: Screw Terminal

5069-RTB64-Spring: Spring Terminal

Attention when wiring:

MOD power supply voltage range: 18-32V DC, maximum current 10A (total current through RTB does not exceed 10A).

The SA power supply can be connected to DC or AC (0-240V AC, 47-63 Hz), with a maximum current of 10A.

Each power terminal has overcurrent protection (there is no fuse inside the controller, and an external power supply is required to provide current limiting).

Troubleshooting: If the controller restarts intermittently, measure whether the MOD power terminal voltage is below 18V or has excessive ripple. If the SA power supply is short circuited, the controller will report a module fault and the on-site wiring needs to be checked.

Compatibility with communication with other controllers

The CompactLogix 5380/5480 can communicate with the following controllers via EtherNet/IP:

CompactLogix 5370/5380/5480

ControlLogix 5570/5580

GuardLogix 5570/5580 (Safety)

1768 CompactLogix、 1769 Modular CompactLogix, 1769 Integrated CompactLogix

1789 SoftLogix 5800

PowerFlex with DriveLogix

1785 PLC-5 (requires 1761-NET-ENI serial port to Ethernet conversion)

1747 SLC (requires built-in Ethernet port or 1761-NET-ENI)

1761/1762/1763/1764/1766 MicroLogix (some require 1761-NET-ENI)

Attention: When communicating with the old PLC-5 or SLC, it is necessary to configure the message command (MSG) and set the correct communication path.

The particularity of CompactLogix 5480

The CompactLogix 5480 is the flagship of the family, with a built-in Windows 10 IoT Enterprise operating system that runs in parallel with the Logix control engine. Its characteristics:

Three types of Ethernet ports: three for the Logix engine (supporting DLR/linear/star), and one independent embedded Ethernet port for Windows.

USB 3.0 ports: Two, capable of connecting external devices such as keyboards and mice.

DisplayPort: Directly connect to a monitor and run Windows applications such as FactoryTalk View SE.

User memory: Logix engine 3-20 MB, Windows system comes with 6 GB RAM+64 GB SSD.

Motion control: up to 512 axes, with a maximum of 150 position ring drive axes (5069-L4200ERMW).

Installation direction: If Compact 5000 I/O is not installed next to the controller, the 5480 can be installed in any direction (horizontal or vertical), but it is recommended to install horizontally to ensure heat dissipation.

Safety certification: The 5480 series has not obtained ATEX/IECEx explosion-proof certification (compared to GuardLogix 5380 which has Ex nA or Ex ec certification), therefore it cannot be used in hazardous areas.

Common fault codes and quick troubleshooting table

Possible causes and solutions for the fault phenomenon

The OK light flashes red. The controller is not programmed or the program is lost. Download the program through Logix Designer; Check SD card loading configuration

I/O module displays yellow triangle module mismatch or connection interruption. Check if the module type and configuration are consistent; Rescan the I/O tree

Ethernet port LINK light not on, network cable fault or switch port dead test network cable; Replace the switch port; Check if ports are misused in Dual IP mode

Stop the security task. If the security signature is invalid or the security logic is incorrect, reload the security program with a valid signature; Check the wiring of the safety circuit

SD card loading failed due to incorrect card format or file damage. Use the controller to reformat the SD card (through the "Storage" operation in Logix Designer)

Excessive tracking error of the motion axis increases the cycle time of the motion task due to high network load or insufficient cycle time; Put sports data in a separate VLAN or use DLR ring network

Controller overheating shutdown environment temperature exceeding 60 ° C or insufficient spacing, increase cabinet cooling; Check if it meets the minimum spacing requirements (see Chapter 4)